Hybrid Concrete Construction

Maximising the potential of concrete by combining

precast and in-situ concrete
 2 HYBRID CONCRETE CONSTRUCTION

Contents Introduction
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hybrid construction combines the most appropriate
materials and methods of construction. The search
Benefits of hybrid concrete construction . . . . . . . . . . . . . . . . . . 3 for greater economy, in terms of material costs and
reduced construction time, has resulted in innovative
Hybrid options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 approaches that seek to combine construction
materials and methods to optimum effect. Hybrid
Design and procurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 concrete construction (HCC) is one such development
that combines in-situ and precast concrete to maximise
Case study 1: Jubilee Library, Brighton . . . . . . . . . . . . . . . . . . . 13
the benefits of both forms of concrete construction.
Case study 2: Hilton Hotel Tower Bridge, London . . . . . . . . 14 Hybrid concrete construction embraces a number of different forms of
structural frame, but in all cases precast concrete and cast in situ concrete
Case study 3: West Quay car park, Southampton . . . . . . . . . 14 elements are used where they are most appropriate for the project. HCC
produces simple, buildable and economic structures which result in
Case study 4: Homer Road, London . . . . . . . . . . . . . . . . . . . . . 15 faster, safer construction and reduced costs. There are many benefits of
concrete which are shared by both precast and in-situ concrete. Many of
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 these are listed in Table 1 and described in the Benefits of Hybrid Concrete
Construction section (page 3).

Table 1: Benefits of hybrid concrete construction

Precast concrete Precast or in-situ In-situ concrete

concrete

Economic for Inherent fire Economic for

repetitive elements resistance bespoke areas
Long clear spans Durability Continuity
(structural efficiency)
Speed of erection Sustainability Inherent robustness

Buildability Acoustic Design flexibility

performance
High-quality finishes Thermal mass Services coordination
and consistency of later in programme
colour
Accuracy Prestressing Locally sourced
materials
Reduced propping Mouldability Short lead-in times
on site
Reduced skilled Low vibration
labour on site characteristics

Cover image:
Main: Ideas Store, London, courtesy of Hanson

Benefits of hybrid concrete
construction
Hybrid concrete construction produces simple,
buildable and economic structures. It delivers increased
prefabrication, faster construction and consistent
performance. HCC can achieve very significant cost
savings and can satisfy the requirements of the most
demanding of clients.
Buildability
The key advantage of HCC is its buildability. Because precast and cast in situ
concrete are used where most appropriate, construction becomes relatively
simple and logical. The use of HCC encourages design and construction
decisions to be resolved at design stage. This means, for example, that
precast elements can be manufactured, stored at the factory and delivered
‘just-in-time’ to site. They can then be lifted from delivery truck to final
position in a single crane movement, eliminating the need for site storage
and reducing crane hook time.
Traditional formwork typically accounts for 40 per cent of in-situ frame
costs and is dependent on weather and labour. The use of HCC means
that a percentage of the frame is manufactured in a weather-proof factory,
resulting in faster construction.
Cost
Although the structural frame of a building represents only 10 per
cent of the total construction cost, the choice of material has dramatic
consequences for subsequent processes. Hybrid construction can reduce
frame costs by using precast concrete for the repetitive elements, or to act
Home Office Headquarters, London. The HCC frame was designed specifically for the project. This image shows the installation of the precast beams.
HYBRID CONCRETE CONSTRUCTION 3
as permanent formwork. In-situ concrete is more cost-effective for large
volumes (due to reduced transport costs) for tying the frame together and
for bespoke areas. Using the two together maximises the cost efficiency.
Speed
Speed of construction depends on designs which are easy to procure and
construct. HCC takes a proportion of work away from the site and into
the factory, reducing the duration of operations critical to the building
programme on site. The precast process takes place in a controlled
environment, unaffected by weather. Rigorous inspection before installation
removes causes of delay on site. Developments and innovation in formwork
systems and concrete technology mean that in-situ elements of a HCC
structure can also be completed within tight programme constraints.
Some HCC techniques can reduce or eliminate following trades, e.g.
installing ceilings and finishes. This enables even faster programme times
but requires greater co-ordination and care in detailing and protection on
site.
Safety
A high proportion of hybrid concrete construction is carried out in the
precast factory by experienced personnel. On site, the innovative use of HCC
and the improved buildability helps ensure that each safety plan is prepared
on the individual project’s merits.
HCC can reduce the potential for accidents by providing successive work
platforms and a tidier site. If precast spandrel beams are used they can
provide immediate edge protection.
4 HYBRID CONCRETE CONSTRUCTION

Benefits of both in-situ and precast Sustainability

concrete Concrete is a local product to the UK, manufactured from plentiful

resources under strict regulations ensuring the highest environmental and
social standards. Therefore the sector has been able to embrace responsible
Precast or in-situ concrete sourcing and manufacturers have gained accreditation at the highest level
Inherent fire resistance for their concrete products. This is recognised in sustainability assessment
methods, enabling designers to gain maximum credits by choosing
Durability concrete.
Sustainability
Thermal mass
Acoustic performance
Buildings with concrete frames have embodied energy and CO2 of a
Thermal mass similar order to equivalent buildings constructed from other materials. For
all buildings the operational energy consumption is far more significant
Prestressing
than that during construction, but concrete buildings utilising thermal
Mouldability mass can reduce this impact on the environment by moderating building
temperatures, delaying the peak temperatures to later in the day and
Low vibration characteristics thus minimising the need for air-conditioning. Use of thermal mass as
part of passive solar designs can also reduce energy demands for heating
during the winter, particularly in residential and education sectors. Further
information is available from the document Utilisation of Thermal Mass in
Non-Residential Buildings [3].
Fire resistance
Concrete has inherent fire resistance, which is present during all
Internal temperature Internal temperature External
construction phases, and is achieved without the application of additional with high thermal mass with low thermal mass temperature
treatments. The fire resistance is also maintenance free. Concrete has the
best European fire rating possible because it does not burn and has low
Peak temperature Up to 6-8oC difference
heat conductance. Further information can be found in Concrete and Fire delayed by up to between peak external
Safety [1] available from www.concretecentre.com/publications. six hours and internal temperature

Durability 30oC

A well-detailed concrete frame is expected to have a long life and require

very little maintenance. It should easily be able to achieve a 60-year
design life and, with careful attention to the specification of the cover and
concrete properties, should be able to achieve 100 years even in aggressive
environments. BS 8500 [2] is the British Standard for durability and gives
advice for various environments.
15oC

Day Night Day

Figure 1: Stabilising effect of thermal mass on internal temperature .

An award winning hybrid structure . Jubilee Library, Brighton . Courtesy of Bennetts Associates . For the full case study, see page 13 .
 HYBRID CONCRETE CONSTRUCTION 5

Acoustic performance
Concrete is a very good sound insulator, even when the source of
noise is an impact on the face of the concrete. For this reason concrete
floors and walls are often used in residential accommodation, including
flats, hotels and student residences, to prevent the passage of sound
between units.

Concrete can also be used to prevent the sound escaping into or out of
a building. A good example would be the use of concrete floors beneath
mechanical plant on the roof of a building to prevent the noise penetrating
to the habitable areas.

Prestressing
Prestressing concrete, using tensioned high-strength steel, reduces or
even eliminates tensile stresses and cracks. This gives rise to a range of
benefits that exceed those found in normally reinforced concrete sections.
Benefits include increased spans, stiffness and watertightness, and reduced
construction depths, self-weights and deflections. Prestressing can be
carried out before or after casting the concrete. Tensioning the prestressing
steel before casting (i.e. pre-tensioning) tends to be carried out in factories
e.g. in producing precast floor units. Post-tensioning is more usually carried
out on site using in-situ concrete.

Mouldability
Concrete can be formed into any shape and this can be achieved with
either precast or in-situ concrete. Concrete provides the opportunity to
create unusual shapes at a small cost premium. Repetition of elements
can make even complex shapes affordable for projects which are cost-
driven. This can be particularly beneficial if circular columns are required
for aesthetic reasons or where columns need to be contained in walls,
e.g. for apartments. Concrete can also be used for curved beams, unusual
plan shapes and shell structures. The layout of the vertical structure can be
arranged to suit the use of the building rather than having rigidly to follow
a structural grid.

Vibration control
For some types of buildings the control of vibrations induced by people
walking across the floor plate are important. This is particularly the case
for hospitals and laboratories containing sensitive equipment, but even
in offices long slender spans can vibrate excessively. The inherent mass
of concrete means that concrete floors generally meet vibration criteria
at no extra cost as they do not require additional stiffening. For more
stringent criteria, such as for laboratories or hospital operating theatres,
the additional cost to meet vibration criteria is small compared with other
structural materials.

An independent study [4] into the vibration performance of different

structural forms in hospitals has confirmed that concrete can normally be
readily designed for the most complete control of vibration over whole
areas, without the need for significantly thicker floor slabs than those used
for a basic ‘office’ structure. This gives great flexibility for change in use and
avoids the cost penalties of providing this extra mass and stiffness.

Homer Road speculative office development showing the tapered edge of

the precast concrete perimeter unit. Courtesy of Foggo Associates. For the
full case study, see page 15.
6 HYBRID CONCRETE CONSTRUCTION

Benefits of precast concrete supplies ensuring consistency of supply and giving greater control of the
constituent materials used.

Acceptability of finishes and consistency of tone can be confirmed prior to

Precast concrete
leaving the factory. A wide choice of precast concrete cladding finishes and
Economic for repetitive elements facings is available, including:
Long clear spans ¢ Surface retarding and wash-off
¢ Rubbing
Speed of erection
¢ Abrasive blasting
Buildability
¢ Bush hammering
High-quality finishes and consistency of colour ¢ Mechanical grinding and polishing
Accuracy ¢ Acid etching.

Reduced propping on site More information on architectural finishes can be found in Precast Concrete
Reduced skilled labour on site in Buildings [5].

Accuracy
Precast elements are cast to close tolerances, and checked in the factory
Economic for repetitive elements before delivery to site.

Using precast elements reduces requirements for falsework; this saves cost Reduced propping on site
through reduced resources and by shortening the programme. There is
Depending on the type of element used, there may be no temporary
also less reliance on wet trades, which can be delayed by unfavourable
propping or minimal propping required. This increases productivity and
weather conditions. However, to maximise economy the mould created
reduces the temporary works.
to cast the concrete should be re-used as much as possible, thus precast
concrete is most economic where repetition is maximised. Repetition does
Reduced skilled labour on site
not mean the finished building will be uninspiring; designers can produce
aesthetically pleasing designs by innovative use of repeat elements. The production of precast concrete takes place in a factory environment,
removing labour requirements from site. The factory work is carried out in
Long clear spans an internal environment at safe working heights.
Reducing the number of columns is often important in developments such
as offices, sports stadia and car parks. Prestressing the concrete can deliver
these longer spans or shallower construction depths.

Speed of erection
Speed of erection and tight construction programmes are primary
considerations in many building projects. To maximise the speed of
construction with precast elements two critical factors should be taken into
consideration:
¢ The building layout should be designed to maximise repetition of
precast units
¢ Construction details should be designed to maximise the number of
standardised components.
Toyota UK Headquarters is an exposed precast and hidden in-situ reinforced concrete
Buildability hybrid building. Courtesy of Trent Concrete.

Precast elements are designed by specialist precast concrete designers.

Within their design they consider the erection sequence and process so
that the elements are engineered to be constructed easily. This planning
makes the frame highly buildable.

High-quality finishes and consistent colour

High-quality consistent finishes are generally achieved through the use of
robust, purpose-made formwork and dedicated concrete mix designs in
a factory environment. Sample finishes can be approved by the client as a
benchmark for the project requirements. For visual concrete that is to be
exposed to exploit the thermal mass of concrete construction, consistency
of tone and texture is important. Precast factories have dedicated concrete
Precast glazed insulated panels. These site-ready panels can reduce programme time
on site. Courtesy of Roger Bullivant Ltd.
 HYBRID CONCRETE CONSTRUCTION 7

Benefits of in-situ concrete Inherent robustness

An in-situ concrete frame is generally very robust because of its
In-situ concrete monolithic nature. Usually the tying requirements of the Building
Regulations to avoid disproportionate collapse are met with normal
Economic for bespoke areas detailing of concrete. In-situ concrete areas can be used with precast
Continuity (structural efficiency) concrete elements to provide the necessary tying without having to
introduce ties specifically for this role. How to Design Concrete Buildings
Inherent robustness to Satisfy Disproportionate Collapse Requirements [6] is available at
Flexibility www.concretecentre.com/publications.

Services coordination later in programme Flexibility

Locally sourced materials In-situ concrete is a flexible material to use; it can be cast into an infinite
Short leadt-in times number of shapes, and can be varied from floor to floor. It is available
throughout the UK from concrete suppliers and placed by experienced
contractors.

Services coordination later in programme

Economic for bespoke areas
With in-situ concrete the location of services penetrations can occur later in
In-situ concrete can be cost-effective for bespoke areas and can therefore
the programme. This is because the final design of the concrete elements
be combined effectively with precast concrete for more unusual areas or
can occur later in the overall programme than for elements fabricated
elements of a building.
off-site.
Continuity (structural efficiency)
Locally sourced materials
In-situ concrete is generally designed to maximise the benefit of the
In-situ concrete is available close to project sites, wherever they are in the UK.
monolithic structure, by use of structural continuity which increases spans
Many ready-mix plants are located where the aggregate is extracted or, where
and stiffness and reduces construction depths.
this is not possible, aggregate is often transported by rail or water.

Short lead-in times

The lead-in time for in-situ concrete can be considerably shorter than other
materials, this is because the materials are readily available and assembled
in position. This can result in in-situ concrete delivering quickest overall
construction times.

The average distance from a concrete plant to any building site in the UK is 8km, providing a sustainable solution to transportation.
8 HYBRID CONCRETE CONSTRUCTION

Hybrid options
The ideal combination of precast and in-situ concrete is influenced by project requirements. There is a wide
range of possible options, a selection of which is presented here as representative of current UK practice. It is not
intended to be an exhaustive list.

Type 1 Type 2 Type 3

Precast twin wall and lattice girder Precast column and edge beam Precast column and floor units
slab with in-situ concrete with in-situ floor slab with in-situ beams

Type 4 Type 5 Type 6

In-situ columns or walls and beams In-situ column and structural topping In-situ columns with lattice girder slabs
with precast floor units with precast beams and floor units with optional spherical void formers

Hybrid
Final version
Owen Brooker
27.11.08

Ease of Minimises Suitability Clear spans Deflection Minimise Soffit can Maximises Temporary
services storey for holes control materials be exposed off-site works
distribution height construction minimised

Type 1

Type 2

Type 3

Type 4

Type 5

Type 6

Excellent Good Can be used


Precast twin wall and lattice girder
slab with in-situ concrete
Hybrid concrete wall panels are increasingly being specified on projects
throughout the UK and are often known as ‘twin wall’. They comprise two
skins of precast concrete connected by steel lattices, which are filled with
in-situ concrete on site.
The external skins of the twin wall system are factory made, typically using
steel moulds. This results in a high-quality finish. The panel surface quality
is suitable to receive a plaster finish or wallpaper. The panel surface is not
normally appropriate for visual concrete. Joints either have to be expressed
as a feature of the finish, or concealed. This type of HCC offers advantages
to the contractor in terms of speed of construction, as well as reducing
the number of skilled site staff required to construct walls. Often the twin
wall system is combined with the use of lattice girder precast soffit slabs,
with or without spherical void formers (Type 6, shown on page 8). These
provide permanent shuttering for an in-situ slab that can be relatively easily
combined with the wall system. Spans of up to 8m are common and spans
up to 14m are possible. (The manufacturer should be consulted early on to
ensure the longer spans are viable.)
One Coleman Street, London. Inset: Off loading twin wall units. Courtesy of John Doyle Construction.
HYBRID CONCRETE CONSTRUCTION 9
Potential structural uses of the twin wall system include:
¢ Cellular type structures for residential use
¢ Walls carrying vertical loads only
¢ Shear and core walls; this has significant implications for the design
¢ Retaining walls; this has significant implications for the design
¢ ‘Single sided’ formwork situations, where there is no access to one side
of the wall to erect formwork, for example wall construction on a party
wall line against neighbouring buildings.
The major advantage is that it is an ‘in-situ structure’, fully continuous and
tied together, but without the need for shuttering on site. Twin wall can
also be cast with fully trimmed openings and with ducts for cables and
other services.
Advantages:
¢ Quality finish for walls and soffits enabling use of thermal mass
¢ No formwork for vertical structure and horizontal structure when lattice
girder slabs are used
¢ Structural connection between wall and slabs relies on in-situ
reinforced concrete detail and is inherently robust
¢ Reduced propping
Disadvantages:
¢ Propping of lattice girder slabs is required prior to sufficient strength
gain of in-situ concrete
¢ The smaller dimension of the precast units is typically a maximum of
3.6m, so joints in walls and soffits must be dealt with (expressed or
concealed)
¢ Reduced flexibility of layout as this option requires walls rather than
columns.
10 HYBRID CONCRETE CONSTRUCTION
Precast column with in-situ floor
slab
The combination of an in-situ slab, e.g. post-tensioned flat slab, with precast
columns can provide an economic and fast construction system. Precast
concrete edge beams may also be used to avoid edge shutters on site
and to allow perimeter reinforcement, cladding fixings or prestressing
anchorages to be cast in. This reduces the time required for reinforcement
fixing and erecting the formwork.
The maximum span for this form of construction depends largely on
whether the in-situ slab is post-tensioned. For flat slabs with spans greater
than 10m punching shear is likely to be a critical design issue.
This form of construction relies on the structure being braced. This is
achieved by the lift core(s) or separate shear walls.
Advantages:
¢ Columns can be erected quickly
¢ Quality finish for columns
¢ Precast edge beam contains post-tensioning anchorages (if required),
slab edge reinforcement and cladding fixings, and avoids need for slab
edge shuttering
¢ Can be used with a variety of in-situ slabs, selected to suit individual
project requirements
¢ More flexible for late changes
Disadvantages:
¢ In-situ slab requires falsework, formwork and curing time
Precast column and floor units with
in-situ beams
This form of construction allows a high proportion of the structure to be
manufactured in quality controlled factory conditions off site leading to fast
construction on site.
A variety of precast floor products could be used with this type of
construction, including hollowcore units, double tees, lattice girder
slabs (with or without spherical void formers) or bespoke coffered floor
units. The latter have successfully been used in high quality buildings
designed for energy efficiency, where the lighting, architectural features
and cooling systems have all been incorporated into the unit.
Advantages:
¢ Vertical structure can be erected quickly; no formwork required
¢ Precast floor structure can be erected quickly; no formwork required
¢ Quality finish for columns and soffits (although this is not always
possible with hollowcore units)
¢ Structural connection between precast elements is via standard
reinforced or post-tensioned concrete
Disadvantages:
¢ Precast flooring must be temporarily propped
¢ Sealing between precast units is required
In-situ columns or walls and beams
with precast floor units
A variety of precast floor products could be used with this type of
construction, including hollowcore units, double tees, lattice girder slabs
(with or without spherical void formers) or bespoke coffered floor units.
Advantages:
¢ Precast floor structure can be erected quickly; no formwork required.
¢ Quality finish for soffits (although this is not always possible with
hollowcore units)
¢ Short lead time for standard precast product
Disadvantages:
¢ Precast flooring must be temporarily propped
¢ Sealing between precast units is required
In-situ column and structural
topping with precast beams and
floor units
In this form of construction the floor consists entirely of precast elements,
which are tied together with an in-situ structural topping. The column
formwork can be designed as a temporary support for the precast beams
and slabs to reduce the requirement for propping of the precast floor.
The joint between the beam and columns and any structural screed is
concreted with the columns to form a monolithic, robust structure.
This system requires particular attention to the connection details between
the precast beam and floor units. It should be ensured that adequate
structural ties are provided to achieve a robust structure.
Advantages:
¢ Precast floor structure can be erected quickly
¢ Precast beams support precast floor units, minimising floor propping
¢ Precast quality finish for soffits (although this is not always possible with
hollowcore units)
¢ Formwork for in-situ columns can be used to prop precast beams
¢ Structural connection between precast elements is via standard
reinforced concrete
¢ In-situ structural topping to beam permits beams to be continuous over
columns
Disadvantages:
¢ Downstand beams need to be coordinated with the services
distribution
 HYBRID CONCRETE CONSTRUCTION 11

INSTALL FORMWORK & PRECAST BEAM

In-situ columns with lattice girder INSTALL FORMWORK & PRECAST BEAM
INSTALL FORMWORK & PRECAST
2
Lifting BEAM
with the crane

slabs with optional spherical void INSTALL FORMWORK & PRECAST BEAM
Safety 2 beam
Precast Safety

formers
Lifting with
2
the crane

Moving Lifting with

2 the crane
formwork Safety
1 Precast
Lifting with beam
the crane Safety
Safety Precast beam Steel
Safety
The main feature of this system is the use of the lattice girder panels Moving Safety Precast beam formwork
Safety
to act as permanent formwork for a flat slab. A variation is to include formwork
Level +11
Moving
formwork 1 Steel
spherical void formers. These reduce the self-weight of the slab for only Moving
formwork 1 Back-propping (if necessary) formwork
Steel
a small reduction in flexural strength and stiffness. Lattice girders and Level +1 formwork
Steel
Level +1 formwork
void former cages are cast into concrete panels containing reinforcement Level +1 Back-propping (if necessary)
in two directions, providing a precast panel that acts as the permanent Back-propping (if necessary)
Back-propping (if necessary)
formwork. If the spherical void formers are used, they are removed in areas
of high shear where a solid section provides greater shear resistance. The Stage 1:
slab may be designed as a flat slab to reduce the overall floor zone of the Column formwork erected to provide temporary support for the
precast beams.
POURING Precast beams positioned on the column formwork
COLUMNS
building and to simplify installation of services. Propping of the panels
with beam rebars projecting into the column stitch.
will be required. The quality of the factory produced soffits provides the
POURING COLUMNS
opportunity to take advantage of the thermal mass properties of the
POURING COLUMNS Concreting (column & stitch)
concrete slab by exposing them. POURING COLUMNS
3 Reinforcement

A
Safety
Level +2 Concreting (column & stitch)
Precast beam
Advantages: 3
Concreting (column & stitch) Reinforcement

A A A
3
Concreting Propping& stitch)
(column Safety Reinforcement
¢ Precast floor structure can be erected quickly; no formwork required Level +2 3 Precast
4 beam
Reinforcement
Safety
Level +2 Steel Precast beam
¢ Structural connection between precast elements is via standard Level +2 formwork Propping
Precast beam
Safety

reinforced concrete Level +1 4

Propping
Steel 4
Propping

A
¢ Quality finish for soffits formwork
Steel 4
Level +1 formwork
Steel
¢ More flexible for late changes Level +1 formwork

A A A
Level +1

Disadvantages:
¢ Precast flooring must be temporarily propped
Stage 2:
Cast in situ columns poured to the top of the precast beams:
stitching together the beam/column joint.
PLACING HOLLOWCORE PLANKS

PLACING HOLLOWCORE PLANKS

Lifting
PLACING HOLLOWCORE PLANKS Hollowcore
PLACING HOLLOWCORE PLANKS 5

Level +2 Lifting
Hollowcore
Lifting 5
4 Propping Hollowcore
Props Lifting 5
Level +2 Hollowcore
5
Level +2
Level +2 4 Propping
Props
Level +1 4 Propping
Props
4 Propping
Props
Level +1
Level +1
Level +1

Stage 3:
Hollowcore slabs placed between the beams.

POURING TOPPING
Concreting
POURING TOPPING Topping
Finishing
POURING TOPPING 7 Concreting 6 Slab Reinforcement
POURING TOPPING
Concreting
Level +2Finishing Topping
Concreting
7
Topping 6 Slab Reinforcement
Finishing
Finishing 7
Topping 6 Slab Reinforcement
Level +2 7
FREE AREA 6 Slab Reinforcement
Level +2
Level +2
Level +1 FREE AREA
FREE AREA
FREE AREA
Level +1
Level +1 Stage 4:
Slabs
Level +1 topped with 50mm cast in situ concrete to achieve
a monolithic structural unit.

Spherical void formers The Home Office headquarters hybrid concrete structure was constructed using the
above four stage sequence.
12 HYBRID CONCRETE CONSTRUCTION
Design and procurement
Design
Hybrid concrete construction can be designed as a normal reinforced
concrete building, with full composite action between in-situ and precast
elements. The design should also consider the construction phase, as one
of the load cases is normally precast concrete elements supporting the
weight of wet in-situ concrete. An additional stage may be considered
if de-propping happens before the in-situ concrete reaches its design
strength.
The interface between precast and in-situ concrete elements
should be considered in the design process and a detailed
guide, Design of Hybrid Concrete Buildings [7] is available from
www.concretecentre.com/publications. This gives essential
guidance on the key considerations.
Initial sizing
The initial sizing of the elements for HCC can be carried out using normal
methods, for example The Concrete Centre publications Economic Concrete
Frame Elements [8] and Concrete Buildings Scheme Design Manual [9] both
give guidance on sizing concrete frames.
Inland Revenue, Nottingham, interior of building. The design fully exploited the potential of precast concrete and prefabrication of other major structural elements to achieve real
buildability. Image: Martine Hamilton-Knight/Built Vision.
Procurement
Many UK engineers are experienced in using in-situ concrete, but may feel
less confident specifying precast concrete. To obtain the maximum benefit,
it is advisable to involve the precast concrete manufacturer at the earliest
opportunity. The precast industry is able to give initial advice.
The publication Best Practice Guidance for Hybrid Concrete Construction
[10] looks at the procurement process from concept stage through to
design and construction, suggesting processes that allow the capture of
best practice. It is supported by a number of case studies. The guidance
explains the benefits that result from:
¢ Early involvement of specialist contractors
¢ Using a lead frame contractor
¢ Using best value philosophy
¢ Holding planned workshops
¢ Measuring performance
¢ Trust
¢ Close cooperation – with an emphasis on partnering.
It is recommended that this guidance is used to maximise the advantages
of using HCC.
 HYBRID CONCRETE CONSTRUCTION 13

Case study 1: Jubilee Library

The Jubilee Library, Brighton has been lauded for its design values and
sustainability performance. It has won numerous accolades and achieved a
BREEAM rating of ‘Excellent’. A mixture of precast and in-situ concrete was
used to meet these high standards.

Construction
The building consists of four storeys, with reading rooms, meeting rooms and
staff accommodation situated either side of a central, double-height atrium,
itself built on two floors. The central space was constructed using an in-situ
concrete slab supported by a series of eight tree-like
in-situ concrete columns with fins. The thermal mass of the concrete assists
with moderating the temperature fluctuations within the building.

Elsewhere, 260mm thick precast hollowcore units have been used as

part of a Termodeck system. Air is pumped through the cores in the units
to heat or cool the building as necessary; again the thermal mass of the
concrete is used to minimise the energy required for heating and cooling.

What HCC brought to the project

Concrete was a key component of the buildings heating and cooling
systems. A variety of concrete elements were used to suit specific
situations. The hollowcore units provided the ducts for the air flow. Precast
was also used where a high quality finish was required. In-situ concrete was
used for larger floor areas to avoid visible joints, and for the feature fins.

Project team:
Architect: Bennetts Associates with Lomax, Cassidy and Edwards Architects
Structural engineer: SKM Anthony Hunt
Contractor: Llewellyn
Concrete frame contractor: Gallaghers
14 HYBRID CONCRETE CONSTRUCTION
Case study 2:
Hilton Hotel,
Tower Bridge
The Hilton Hotel, Tower Bridge is located on the south bank overlooking the
river Thames. It is 13-storeys high and contains 255 bedrooms. The lower
three storeys contain public spaces and a 500-seat conference centre.
Why hybrid concrete construction was chosen
The twin wall solution, with lattice girder slabs was proposed as an
alternative to fully cast in situ walls and slabs. This proposal allowed the
contractor to reduce the frame construction programme enabling earlier
opening of the hotel.
Construction
The building has a double storey height basement over part of the area
with a conventional concrete frame for the lower storeys. Above the public
spaces the vertical structure consists of twin wall precast units and floors
that use lattice girder slabs. The lattice girder slabs were lifted into position
with the edge protection already in place.
What HCC brought to the project
The use of hybrid concrete gave a fast construction programme – each floor
was completed in just five days, including placing the bathroom pods. The
precast walls, which were used for all the dividing walls and soffits, gave a
high-quality, accurate finish and minimised following trades.
The use of precast lattice girder slabs gave a safe working platform for fixing
reinforcement and pouring the topping concrete. The lattice girder slabs also
reduced the falsework and propping requirements allowing the bathroom
pods to be lifted into position before placing the floor above.
Overall, compared to other construction methods, the site was cleaner and
there was less construction noise.
Project team
Architect: Jestico & Whites
Structural engineer: Adams Kara Taylor
Cost consultant: EC Harris
Construction manager: Bovis Lend Lease
Concrete frame contractor: John Doyle Construction
Case study 3:
West Quay car park
The West Quay car park is one of the largest multi-storey car parks in the
UK. The structure is 95m long, 95m wide and 20m high – eight storeys
comprising 15 split levels with a 2m clear headroom throughout. Access to
the car park is by means of seven staircases and two double lifts.
Why hybrid concrete construction was chosen
At scheme design stage the design team considered various options for
the structural frame, before selecting a HCC structure based on precast
concrete double-tee floor slabs on to cast in situ concrete beam-and-
column frames. The decision to use HCC was based on a ‘value engineering’
exercise. By combining the cost advantages of cast in situ concrete with the
speed of assembly of precast, meant that the structure could be completed
on time and within budget.
Construction
The precast concrete double-tee floor slabs span 15.8m and are 2.4m wide,
matching the width of a standard car parking bay and fitting neatly into the
7.2m grid in the east-west direction. The cast in situ concrete beams were
cast with nibs projecting at both sides and the ends of the slabs were cast
with extended scarf joints; they rest on the nibs and create a 300mm wide
channel for service trunking. The east wall of the car park takes the form of
a sloping buttress clad with precast concrete panels with a reconstructed
stone mix and knapped flint aggregate inserts. At upper levels the car park
is clad with precast spandrel panels of reconstructed stone. The panels
were doweled to the cast in situ concrete structure with cast-in sockets.
What HCC brought to the project
The use of HCC allowed the project to be completed on time and within
budget, with a remarkable lack of interface problems. In particular the
advantages of precast concrete double-tee floor slabs were fully realised;
they proved to be a positive way to create large areas of floor very quickly,
whilst maintaining a high quality finish.
Project team
Architect: BDP
Structural engineer: Pell Frischmann
D & B contractor: Sir Robert McAlpine
D & B engineer: Sir Robert McAlpine Design Group
Precast floors: Tarmac
Precast concrete cladding: The Marble Mosaic Company
 HYBRID CONCRETE CONSTRUCTION 15

Case study 4: Homer Road

Why hybrid concrete construction was chosen
With the Homer Road office building, hybrid concrete construction was
used to create a structure which allows full continuity to occur between
the vertical and horizontal structural elements, thus providing a stiff sway
framework.
The combination of elements allowed the whole frame to act as a
composite structure without relying on expensive mechanical fixings. This
method of construction produces a rigid frame which is inherently stable
without the need for shear walls or bracing.
HCC was the natural choice of material. It fulfilled the design criteria for a
visible expression of the structure; behind the delicate glazed facades the
precast column and beam structure is clearly visible, needing no further
treatment such as cladding for fire protection. In addition, by exposing the
painted soffits of the concrete floor slabs in the offices, the temperature
and ventilation strategy could exploit the thermal mass potential of the
concrete.
At the perimeter the same principle was used with a slightly different
detail. The spine edge beam was cast between the final row of end plates
(which ran up to the inner side of each perimeter column) on one side
and a special precast perimeter unit on the other side, which creates a
tapered edge to the ceiling soffit. The perimeter unit has a row of precast
holes which allows warm buoyant air rising up the facade to be effectively
captured and cooled by the passive chilled beam elements above the
ceiling panels. Similar precast holes connect each trough and provide
return air paths to the central atrium. The precast perimeter units were cast
with a sculpted feature where they meet the column heads. They were
also used at the atrium and core perimeters, cast in the same moulds with
minor adaptations.
Project team
Architect, engineer and cost consultant: Foggo Associates
Construction manager: Bovis Lend Lease
Precaster: SCC (Structural Concrete Contractors)

Construction
The hybrid concrete structure consists of 430mm diameter precast
columns and precast floor units connected together by means of cast in
situ concrete spine beams. Each floor unit takes the form of a double tee-
section with end plates to each trough. At each column connection

the end plates are cast with a curved ‘cut-out’ to follow part of the column
profile.

Once the precast columns were fixed on site, the double tee-section floor
units were connected to them, positioned so that the curved edge profiles
trimmed the outer edge of the columns. The cast in situ concrete spine
beam was then cast between two rows of end plates, stitching

lower and upper columns and adjacent units together. Between the
longitudinal joints, loop connectors were cast into the units and a
continuous cast in situ beam joined the units together. The floor units are
self-finished and no screed or topping was required.

References
1. THE CONCRETE CENTRE. Concrete and Fire Safety. The Concrete Centre, 2008.
2. BRITISH STANDARDS INSTITUTION. BS 8500 Concrete – Complementary British Standard to BS EN 206-1. BSI, 2006.
3. THE CONCRETE CENTRE, Utilisation of Thermal Mass in Non-Residential Buildings, TCC, 2007
4. ARUP. Hospital floor vibration study. Comparison of possible floor structures with respect to NHS vibration criteria . Research Report, Arup, 2004.
5. THE CONCRETE CENTRE. Precast Concrete in Buildings. The Concrete Centre, 2007.
6. BROOKER, O. How to Design Concrete Buildings to Satisfy Disproportionate Collapse Requirements. The Concrete Centre, 2009.
7. WHITTLE, R & TAYLOR, H. Design of Hybrid Concrete Buildings. The Concrete Centre, 2009.
8. GOODCHILD, C H, WEBSTER & R M, ELLIOTT, K S. Economic Concrete Frame Elements. The Concrete Centre, 2009.
9. BROOKER, O. Concrete Buildings Scheme Design Manual. The Concrete Centre, 2009.
10. GOODCHILD, C H & GLASS, J. Best Practice Guidance for Hybrid Concrete Construction, The Concrete Centre 2004.
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ISBN 978-1-904818-75-5
First published 2010
© MPA – The Concrete Centre 2010

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